Apricus CoolSky Installation Manual

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CoolSky Ltd 42 Milecross Road, Newtownards BT23 4SRTel: +44 (0)28 9182 9470

Email: [email protected]

Company Registration No. NI072166

VAT No. GB 108838970

Copyright 2012 CoolSky


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Apricus Installation Manual

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TABLE OF CONTENTS

Solar Thermal Introduction 3

Technical Specification of The Apricus Collector Range 6

Solar Pumping Station 9Pump Sizing 10

Solar Expansion Vessels 11

Sizing and Designing your Solar System 18

System Sizing 19

Sizing the Solar Cylinder 21

Pipe Type and Size 21

Stagnation & Overheating 22

Connection of Multiple Collectors 25

Balancing Flow through Collectors 25

Wind & Structural Loading 26

Back-Up Heating Source 29

Anti-Scald / Tempering Valves 29

Closed Loop Max Incoming Pressure 29

Maximum Allowable Pressure 29

Electrical Supply 30

Labelling 30

Building Considerations 31Health & Safety Considerations 32

Installation Guidelines 34

Manifold and Bottom Support Track Assembly 35

Other System Components 37

Collector Installation 38

Connection to Plumbing 44

Insulation 44

Installation of the Tubes 46

Commissioning The System 50

Post Installation 52

Clean Up 52

Maintenance & Repair 53

Maintenance Schedule 55

Troubleshooting Guide : 56

Home-Owner Maintenance 60

Glossary of Terms 63

Important Information 64


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Solar Thermal Introduction

Introduction

CoolSky Ltd. are distributors in the U.K. and

Ireland for the Apricus range of Evacuated

Tube Solar Thermal Collectors. Since theirformation in 2002, Apricus have quickly

established themselves as a global company

with offices in USA, France and Australia with

sales in over 30 countries worldwide.

Apricus have a modern manufacturing facility

that includes a 6,500 m2 factory floor,

administration offices and an R&D Centre.

Apricus Collectors conform to the European

Standard EN12975 and carry the European

SolarKeymark Certification (Licence No. 011-

7S161R) as a mark of their quality, reliability

and performance.

SolarKeymark is considered to be equivalent

to MCS Product Certification thereby

qualifying the products for financial

assistance under various funded schemes

where available.

All Apricus collectors, components and

packaging have been carefully designed so

that they can be efficiently recycled at end-

of-life.

Solar Energy

Solar Energy is the planets most abundant

source of energy with the added benefit that

it is both clean and free.

(Source : EU Commission Joint Research Centre)

Whilst the UK and Ireland are considered to

have mild and temperate climates there are

parts of the UK that can receive annualradiation levels equivalent to 65% of the

radiation that is received in places like

Madrid, Spain, making both the UK and

Ireland suitable locations for Evacuated Tube

Solar Thermal Collectors.

The Apricus Evacuated Tube Solar Collector

provides an efficient solution for the capture

of Solar Radiation and is ideal for use in UK

and Irish climatic conditions. Although the

peak solar radiation period in the UK and

Ireland is in the months from May through

to August, the Apricus Evacuated Tube Solar

Collectors are highly efficient and able to

harness the energy of the sun throughout

the year and to also provide a useful

contribution to heating during the off-peak

months.


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Evacuated Tube Solar Thermal Collectors are

able to capture the available Solar Energy

and then transfer it as Thermal Energy to the

water heating system, thereby raising the

temperature in the hot water storage

cylinder, and offsetting the reliance to on

alternative fuels (such as coal, gas, oil or

electric) to provide hot water. Up to 70% of

the domestic hot water requirements can be

met by the Apricus Solar Collectors.

Since solar radiation levels depend uponboth the season and the daily weather

conditions it is always necessary to

incorporate a back-up water heater (typically

standard fossil fuel boilers or electric

immersion heaters) to ensure there is a

sufficient supply of hot water all year round.

Key Components of the Solar

Thermal System

Solar Energy is collected when the sunlight

strikes the black selective absorber contained

inside the evacuated tubes of the Solar

Collector.

Each tube contains a copper heat-pipe that

is in contact with the absorber. The heat-

pipe contains a small quantity of water

under a vacuum environment that allows thewater to start boiling at temperatures as low

as 30C. The water vapour generated when

boiling rapidly rises to the top of the heat

pipe where it condenses and transfers its

thermal energy to the condenser and into

the copper header pipe within the manifold.

Fig. 2 Schematic showing the basic layout of a simple solar thermal

system.

The condensed fluid then flows back down

the heat pipe and is re-heated, thereby

restarting the thermal cycle again.

A circulating pump moves the heat transfer

fluid (a propylene-glycol anti-freeze mixture)

through the copper header pipe within the

manifold and back to the storage cylinder. A

solar heat exchanger coil within the storage

cylinder transfers the thermal energy from

the heat transfer fluid into the water within

the storage cylinder. The cooled fluid then

returns to the collector manifold to be re-

heated.

The operation of the solar loop is controlled

with a temperature differential electronic

controller. This ensures that solar fluid is

only circulated in the solar loop when there

is useful energy to transfer from the

collector into the storage cylinder.

Back-up heating using a conventional fossil

fuel boiler or electrical immersion should

also be provided for periods when solar

radiation is unable to meet the total hot

water demand.


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Apricus Collectors

The Apricus Collectors are available in 3

Standard Models as follows :

APSE-10 10 Tubes

APSE-20 20 Tubes

APSE-30 30 Tubes

All the Apricus Collectors are certified to the

European SolarKeymark Scheme thereby

ensuring the installer and end-user of the

highest standards and quality in materials

and manufacturing, which also qualifies the

collectors for government funded schemes

requiring MCS Certification.

The Apricus Solar Tube consists of a circular

inner absorber tube that is coated with a

selective absorber layer of Al/N on Al. This

selective absorber provides each tube with a

highly selective radiation absorbing surface,

with typical absorption efficiencies of >92%.

The absorber tube is encased within a strong

borosilicate glass enclosure that is then

placed under ultra-high vacuum conditions

to ensure the ultimate performance in terms

of thermal insulation.

A getter coating at the bottom of the tube is

used to maintain the ultra-high vacuum level

within the tube throughout its operational

lifetime and to ensure maximum collector

efficiency is achieved.

Apricus tubes have a round absorber surface

within the tube, and hence, irradiation from

the sun always strikes the absorber surface

in a perpendicular direction. This ensures

optimum collector performance whatever the

time of day, morning, mid-day or afternoon.

This is reflected in the excellent IAM

(Incident Angle Modifier) figures for the

Apricus Collectors which makes them the

ideal choice of collector for the typical UK

and Irish weather conditions where peak

solar radiation is not guaranteed to be atmid-day.


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Technical Specification of The

Apricus Collector Range

Model : APRICUS APSE-10Aperture Area : 0.94 m2

Gross Area : 1.56 m2

Weight (Dry) : 35kg

Fluid Capacity : 0.2litres

Max Pressure : 8 bar

Stagnation Temp: 219C

Absorption : 92%

Emission : 8%

Width x Length : 796 x 2005 mm

Height : 156 mm

Performance Figures :

0 62.6 %

a1 1.595

a2 0.013

Model : APRICUS APSE-20

Aperture Area : 1.88 m2


Weight (Dry) : 64 kg

Fluid Capacity : 0.52 litres


Stagnation Temp : 219C

Absorption : 92%

Emission : 8%


Height : 156 mm


0 62.6 %

a1 1.595

a2 0.013

Model : APRICUS APSE-30Aperture Area : 2.82 m2


Weight (Dry) : 95 kg

Fluid Capacity : 0.71 litres


Stagnation Temp : 219C

Absorption : 92%

Emission : 8%


Height : 156 mm


0 68.7 %

a1 1.505

a2 0.011

Key Features

Manifold :

Material : Anodised Aluminium

Insulation :

Material : 50mm Glass Wool

Conductivity : 0.043 W/mK

Tubes :

Glass : 1.8mm Thick Borosilicate

Absorber : Al-N on Al

Rubber Components :

Material : HTV (UV Stable) Silicone

Max Temp. : 300 C


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Storage Cylinders

Both copper and stainless steel storage

cylinders are available from CoolSky. These

cylinders are specially designed and

optimised for Solar Systems, comply with UK

regulations, and are fully compatible with the

Apricus Solar Collectors. Options are

available for both vented and unvented

systems.

As an added service we are also able to

provide cylinders that are designed and

manufactured to bespoke requirements.

Vented Solar Cylinders

The Standard Easy-Fit Vented Copper

Cylinders are available in either twin coil or

triple coil configurations and are specifically

designed to work in conjunction with the

domestic heating system.

One or two coils are designed to transfer

heat from an independent heating source,

(eg. transferring heat from a central heating

boiler or solid fuel boiler to the water in the

solar cylinder) and the solar coil, which is

manufactured from high efficiency finned

tubes with a large surface area, to transfer

heat from the solar panels into the solar hot

water cylinder with maximum efficiency.

We are also able to supply custom sizes

upon request giving you total flexibility in

the design of your complete system. In

general, solar cylinders are sized to suit the

number of occupants and the solar thermal

panel surface area.

Nominal Diameters :400 mm Only Twin Coil Available

450 mm Twin or Triple Coil



Nominal Heights :

1050 mm, 1200 mm, 1300 mm

1400 mm & 1800 mm

Unvented Solar Cylinders

The Standard Easy-Fit Unvented Stainless

Steel Cylinders are available in a twin coil


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configuration and are specifically designed

to work in conjunction with the domestic

heating system.

Manufactured from Duplex Stainless Steel,

these cylinders provide fast reheat and

recovery and high value insulation. In

addition, for installers they are also light and

easy to handle

Standard Features:

Duplex Stainless Steel

25 Year Guarantee

Fast Reheat/Recovery

High Value Insulation

Nominal Diameter :

545 mm Only Twin Coil Available

Nominal Heights :

1102 mm, 1290 mm, 1478 mm,

1782 mm, 2041 mm

Pressure & Temperature Relief

Valve (PTRV)

The storage tank must be fitted with a PTRV.

All tanks should be supplied as standard

with an approved valve.

Building Regulations

The installation of unvented hot water

cylinder for domestic applications is

regulated under Building Regulation G3 for

England and Wales, Technical Standard P3

for Scotland, Building Regulation P5 for

Northern Ireland and Technical Guidance

Document L for the Republic of Ireland. All

local, relevant and up-to-date regulations

must be adhered to by the installer. An

example schematic safety control layout for

a solar installation to comply with Building

Regulation G3 (England and Wales) is givenin the CIBSE Solar Heating Design and

Installation Guide.

Cool Tip

Rule of Thumb for sizing storage

cylinder in domestic installations:

100 litres per m2

Aperture Area of Collector


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Solar Pumping Station

A Pumping Station is required in the Solar

Loop for the circulation of propylene glycolheat transfer fluid around the solar loop.

The Pumping Stations are provided with the

following key features :

1. Flowmeter, flow rate regulation and

graduated scale regulation gauge 2-12

litre/min.

2. Isolation valves for filling/flushing of the

unit. Connections "M with safety chain

and tap.

3. Circulating Pump - WILO solar STAR

ST15-6ECO, connections 1"BSP - 130mm

class. TF110, VDE, CE.

4. Return side isolation valve DN20, with

integrated bracket. Connection "M

always open on one side.

5. Integrated high temperature check

valves. Closure at 90 and opening at

45. Check valve opening 2kPa (200mm

c.a.)

6. Pressure gauge with integrated safety

relief valve (typ. 6Bar) with discharge

connection point for isolation valve and

expansion vessel.

7. Air stop device with manual integrated

vent.

Model Variations :

The CoolSky range of Pumping Stations areavailable with either Flat Face Male

Gasket Fittings or 22mm Female

Compression Fittings.

A High Head (8m) Pump Version is also

available for larger installations.

2

1

3

4

5

6

7


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Pump Sizing

Sizing of the Solar Pump

The standard CoolSky Twin Line Pumping

station is supplied with a 3-Speed WILO ST

15/6 Eco Pump (6m head) as standard. This

is suitable for most domestic installations

with the pump speed selected to suit the

pressure drop of the piping. Speed 1 is

generally suitable for a short pipe run, such

as on a single-storey house. Speed 3 can

normally service a 3-storey, 90 collector

pressurized system.

If the pipe run is very long or there are more

than 90 tubes in the collector array, a larger

pump may be needed. For these installations

CoolSky supply a Twin Line Pumping station

with a 3-Speed WILO ST 15/8 High Head

Pump (8m head).

If multiple banks of collectors are installed in

parallel, the head loss should be calculated

based on the longest pipe run through a

single bank of collectors and, then, the

pump can be sized to meet the total flow

rate requirements.

Please Note that Drain-back Systems will

typically require a larger rated pump.

Flow Meter

The CoolSky Pumping Staions include a flow

meter as standard to ensure that flow rates

are at suitable levels and can be monitored.

The flow meter includes a restrictor valve

allowing the flow to be adjusted accordingly.

Flow Rate

A suitable flow rate range for each 30 tube

collector is in the range of 1.5 to 3.0 litres

per minute.

Cool Tip

Set the Flow Rate through the

collector array to :

0.1 litre / minute / tube

That is :

1 litre / minute for 10-tubes

2 litres / minute for 20-tubes

3 litres / minute for 30-tubes


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Solar Expansion Vessels

CoolSky offer a range of different sizes of

Zilmet Solar Expansion vessels. These shouldbe sized according to match the

requirements of the system to which they

are connected.

(note : solar expansion vessels should be installed with

the hydraulic connection to the top as this will reduce

heat transfer into the vessel, as shown above)

The Solar Expansion Vessels include 12, 18

and 24 litre versions which have been

specially designed for solar. Other sizes are

available upon request.

The Membrane

Inside the expansion vessel there is a special

Zilan E solar membrane structured as a bag

membrane that separates the gas from the

solar liquid. The development of the

membrane is a result from long term Zilmet

field experience in the installation of vessels

in thermal solar systems.

The membrane is stable with the Pre-Mixed

Propylene-Glycol within the solar loop up to

50% mixtures and has a max. working

temperature of 110 C. The vessel can

accommodate short peaks of 130C glycol

temperature.

The Zilan E solar membrane is also less likely

to trap air and consequently, there is a lower

likelihood of corrosion damage to the steel

vessel.

Expansion Vessels are manufactured in

accordance with the PED 97/23/CE and

EN13831 directives, which mean that they

are fit for use in closed solar energy heating

systems according to DIN 4757 and

EN12977.

Expansion Vessel Technical

SpecificationMax. Operating Pressure: 6bar

Membrane Temperature: 10 - +100C

System Temperature: -10 - +100C

Factory pre-charge: 2.5 bar 20%

Nominal volume: 12, 18 & 24 L

Colour: White

Cool Tip

The Cold-Fill Pressure of the Solar

System should be :

1.3 + (0.1 x Static Height)

Where the Static Height is in

Meters.

Expansion Vessel Pressure should

be re-set to 0.3 Bar less than the

Cold Fill Pressure.


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Expansion Vessel Connection Kit

CoolSky also provide an expansion vessel

connection kit to connect the expansion

vessel to the safety group on the pumping

station. Each kit includes a wall fixing

bracket and a self-closing system isolation

valve (so that the vessel can be removed for

maintenance without draining the fluid from

the system and to facilitate periodic gas

charge checks).

A pre-formed stainless steel flexible hose is

also provided to connect the vessel to the

system at the connection point provided on

the CoolSky Solar Pumping Station.

It is recommended that the Pumping Station

and Expansion Vessel are located as far

hydraulically away in the Solar Loop from the

Solar Collector as is practically possible. This

is to protect the Pumping Station and

Expansion Vessel from the very high

temperatures (i.e. >200 C) that can be

generated by a Vacuum Tube Collector

under stagnation conditions.

Mounting the Expansion Vessel

Always mount solar vessels in a vertical

position and recognised best practice is to

connect to the provided connection port on

the pump station. Where possible, mount

below the pump station to negate heat

transfer.

Avoid mounting in close proximity to the

solar collector where temperatures can

exceed 130C. In cases where this cannot be

avoided, it is highly recommended that the

expansion vessel be installed in conjunction

with a heat protecting intermediate vessel.

Intermediate Vessels

Intermediate vessels are also available and

are recommended on solar thermal systems

where it is likely that temperatures within the

system will exceed the maximum allowable

working temperature of the expansion vessel

Cool Tip

Always check the internal pressure

of the Expansion Vessel before

fitting and reset to 0.3 bar lower

than the intended cold-fill pressure

of the Solar Loop.


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or where the expansion vessel is in close

proximity to the solar collector.

It is particularly important that an

intermediate vessel is installed on systems

where the volume of the collectors exceeds

the volume within the flow and return

pipework. This is because during stagnation

periods, the very hot solar fluid in the

collectors can reach vaporisation point. If this

occurs, the very hot solar fluid is forced out

by the vapour, into the expansion vessel.

Intermediate vessels have inlet/outlet

connections and are installed just before the

main expansion vessel (as shown above). The

heat sink that the intermediate vessel

provides, reduces the working temperature

at the diaphragm, and hence considerablyextends the working life of the expansion

vessel.


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Sizing the Expansion Vessel

To size an Expansion Vessel for a Solar

Application the following equation can be

used :

( ) ( )

Where

VEV = Nominal Expansion Vessel Size [L]

VSYS = Total Volume of System [L]

VSS = Volume of Safety Water Seal [L]

= 0.005 x VSYS

or= 3 Litres

(whichever of above is greater)

= Solar Fluid Expansion Coefficient

= 0.13 for CoolSky Fluid

VCOL = Volume of Collector

= 0.3 Litres for AP-10



n = Number of Collectors

PSV = Pressure Relief Valve Setting

= 6 Bar as CoolSky Standard

PMAX = Allowable Max Pressure in Bar

= PSV (0.1 x PSV)

= 5.4 Bar (for a 6 Bar PRV)

HST = Static Height of System

= Height of Collector from Pump

PEV = Gas Pressure of Expansion Vessel

= 1 + (0.1 x HST)

CoolSky recommend that an additional

safety factor of 1.5 is applied to the VEV

value to account for the possibility of steam

in the solar loop.

Examples of typical domestic Expansion Tank

Capacities are given in the table below.

Apricus AP-30 Collector

Aperture

Area

[m2]

System

Volume

[Litres]

Static

Head

[m]

Expansion

Tank

[Litres]

3 6.9 5 18

10 18

6 7.6 5 18

10 18

9 8.3 5 18

10 18

12 9.0 5 18

10 24

The above are based upon a system using

the Apricus AP-30 Collector with 20 meters

of DN16 Flexible S/S Pipework and a Heat

Exchanger with 2 litre capacity.

The CoolSky Technical Design Team can

provide assistance and support for the sizing

of Solar Expansion Vessels for your

installation if required.


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Solar Thermal Anti-Freeze

CoolSky recommend that a Solar Thermal

Anti-Freeze Fluid is always used in Solar

Collector Installations. CoolSky supply a pre-

mixed (40% propylene glycol, 60% water)

thermal transfer fluid with additional

corrosion inhibitors for use with the Apricus

Solar Collectors. The fluid is supplied in 20

litre drums.

Only Thermal Fluids that are formulated for

use with High Performance Evacuated Tube

Solar Collectors should be used, as these

have special liquid corrosion inhibitors that

are able to vaporise and condense effectively

during normal collector operation.

The fluid is specially developed for

Evacuated Tube Solar Thermal collectors and

provides frost protection to -28C.

Protective goggles and rubber gloves should

be used when handling the thermal fluid.

A full Material Safety Data Sheet (MSDS) is

available from CoolSky Ltd. upon request.

Disposal of the fluid should be in accordance

with local regulations.

Although some Solar Controllers are

provided with a Frost Protect Function it

must be highlighted that this only functions

when there is electrical power provided to

the controller and pumps. In the UK and

Ireland it is not unusual for extremely cold

weather conditions to be accompanied by

power outages due to falling power lines,

thereby rendering the Frost Protection

Function ineffective. Only the use of a

suitable anti-freeze fluid will protect the

solar collector from freezing in the combined

conditions of extreme cold and power

outage.

Apricus Evacuated tubes are not susceptible

to damage in cold weather, and Apricus heat

pipes are protected against damage that

could result from the freezing of the water

inside by the addition of a special frost-

protection additive.

Within the manifold and pipework of the

solar loop a suitable Solar Anti-Freeze fluid

must be used. Contact CoolSky for details of

suitable Anti-Freeze Fluids.

Freeze related damage is not eligible for

warranty claims.

WARNING:

Failure to implement effective (and

fail-safe) freeze protection may result

in rupture of piping and substantial

property damage.


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Solar Heat Dissipater

The Apricus HD-25 is an air to water radiator

designed to dissipate the energy produced

by one AP-30 collector.

Heat dissipation may be necessary when

solar thermal systems are designed for spaceheating applications which may produce

more energy than is needed during warmer

seasons, or for systems where there is an

irregular or low summer demand, for

example, schools, holiday homes and sports

clubs.

The Apricus HD-25 is an ideal solution to

protect from excessive overheating and can

prevent premature ageing of the heat-

transfer fluids used in the solar loop.

Materials of Construction

Piping: Copper (Ag-Zn-Cu brazed)

Fins: 3A21 Grade Aluminium

Case: 3A21 Grade Aluminium

Dimensions

Height: 500mm

Depth: 172mm

Width: 375mm

Heat Transfer Area: 2.8 m2

Gross Weight: 6.6 kg

Inlet/Outlet Pipe: 15 mm x 1.0mm

Heat Loss Performance

When T . 40C, heat dissipation 1.3kW

For optimal performance ensure good

natural air circulation.

Installation Guidelines

Max Flow Rage: 15L/min

Ideal Location: Good natural air flow

Transfer Liquid: Propylene Glycol (50%)


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Safety Valve Discharge Container

A high temperature discharge container has

specially designed to capture any propylene

glycol fluid that is discharged from the

Pressure Relief Vessel on the Solar Pumping

Station and to allow its recovery during

regular maintenance - neatly avoiding the

issues of potential damage to those areas

surrounding the valve.

The unit is manufactured from high

temperature grade plastic material that is

suitable for solar systems and up to 160C

short bursts of glycol/steam. The captured

fluid is visible through the opaque tank

which is supplied complete with a drain

valve.

Technical Specification

Capacity 9.6 litre

Drain valve integral

Size 300 x 270 x 130mm

Clearance required 440mm high

Construction Plastic PE

Ambient temp -5 - +50C

Storage -10 - +60C

Short term discharge 160C


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Sizing and Designing your Solar

System

When starting to design your solar system,

the first issues to consider are regarding theinstallation site and the practicalities of

installing the solar collectors.

This section will provide you with detailed

guidelines about assessing the suitability of

any given site for the installation of the Solar

Collector.

Standard System Designs

CoolSky have developed a standard set of

system designs, which represent the most

commonly installed configurations in the UK

and Ireland. We recommend adhering to

these system designs. Any modifications to

the design should be checked by a qualified

engineer.

When using these designs it is important

prior to installation, to confirm that the

designs meet any local regulations.

All systems must be installed by authorised

persons. Upon completion of the

installation, the system may also need to be

checked by a plumbing inspector prior to

commissioning, depending upon local

regulations.

Free Bespoke Design Service

The CoolSky Technical Design Team can also

offer our customers a full bespoke design

service. System designs and configurations

for both small and large systems can be

tailored to our customers particular

requirements. Contact CoolSky for more

details on our Free Design Service.

Collector Direction

Ideally the collector should face as close to

due South as possible. A deviation of up to

15o to the East or West is acceptable and

will have minimal effect on collector

performance.

If installed due east or west, the solar

collector output will be considerably

reduced, with predominately morning output

or afternoon output for each direction

respectively. However, a dual collector

option exists with one collector facing east

and the second collector facing west. This is

commonly referred to as an East-West

System.

NOTE: Installations at or near due East or

West will mitigate the passive tracking effect

of the round absorbers within the Apricus

evacuative tubes. Collectors should not beinstalled facing a northerly direction.

Collector Orientation

The collector manifold is normally installed

on the flat horizontal plane with the tubes

pointing downwards from the manifold. The

collector must not be installed up-side-down

(tubes pointing upwards) or with tubes lying


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horizontally, as the heat pipes will not

function.

Drain Back Systems

In a drain-back configuration the collector

must be positioned with 2cm of drop per

meter.

Installation Angle

The solar collector must be installed at an

angle of between 20-80o from horizontal to

ensure optimal heat pipe operation. For

optimum summer performance for Domestic

Hot Water applications, as a rule of thumb

the installation angle is typically set as :

Install Angle = 0.7 x Location Latitude

In areas prone to hail, a minimum angle of

45o is advisable. Similarly, in areas prone to

high snow loads, 45o or higher is advisable

to encourage the snow to fall off the

collector surface.

Avoid Shade

Collectors should be located so that shadingdoes not occur between 9am - 3pm which

are the peak sun hours.

Partial shading due to small objects such as

antennas and small flues is not a problem.

If installing multiple rows of collectors

consider the shading of collectors on the

row behind (especially in the winter).

Location of Collector

The collector should be positioned as close

as possible to the storage tank to avoid long

pipe runs.

System Sizing

Domestic System Sizing

For residential domestic water heating

applications basic rules of thumb exist that

allow system sizes to be calculated using the

methodology outlined below.

For space heating or commercial water

heating system the sizing calculations are

more complicated. The CoolSky Technical

Design Team can assist our customers with a

free design service for these systems. Using

special state-of-the-art Solar Thermal design

packages we can assist in the design and

optimisation of all Solar Thermal systems no

matter what the size.

How much hot water is needed?

Ideally the exact daily hot water demand

should be provided through metering.

However, as this is not always available, the

daily demand can be estimated using the

following guidelines :

Cool Tip

Rule of Thumb for Optimum

Installation Angle

0.7 x Location Latitude


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Consumption

Demand

Liters of Hot Water

at 60C per person

LOW 15

MEDIUM 30

HIGH 60

Guidelines for Domestic Hot Water Useage

A general Rule of Thumb for UK / Ireland is

to assume a requirement of 50 litres of Hot

Water per person per day.

The graphic below shows typical sizing

guidelines for collectors when used for

Domestic Hot Water production in the UK

and Ireland.

Guidelines for Collectors Sizing to Match User

Demand for Domestic Hot Water

Commercial Collector Sizing

Sizing a commercial system usually requires

the use of professional modelling software.CoolSky can offer a free design service to

our customers for these jobs.

The table below gives guidelines to typical

Hot Water Demands in commercial

applications.

Type of Building Max. Liters of Hot Water at

60C per person

Restaurant 6

Factory 15

Offices 14

Hotel 5* 136

Hotel (Avg) 114

Sports Facility 40

Hospital 128

Holiday Home 50

Camp Site 40

Typical Hot Water Demands in Commercial Type

Properties.

Cool Tip

Rule of Thumb to Estimate Hot

Water Demand at 60 C in UK andIreland :

50 litres per person per day


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Sizing the Solar Cylinder

Domestic Sizing

The storage cylinder sizes for domestic solar

thermal installations should be sized

according to the following minimum

guidelines :

20 Tubes = 200 Liter cylinder




The storage capacity can be a single tank or

multiple tanks plumbed in parallel.

Using a smaller capacity tank will lead to the

system reaching maximum temperature

sooner, which will often result in wasted

and/or uncollected energy.

If the installed collector area exceeds the

storage capacity of the cylinder there will be

wasted energy and excess heat in sunny

weather. Letting the collector stagnate is an

acceptable means of preventing excessive

tank temperatures during summer, but

stagnation periods should be minimised in

frequency and duration for the sake of

overall system efficiency. Otherwise, the

longevity of the evacuated tubes may be

compromised by more rapidly reducing the

vacuum level.

Commercial Cylinder Sizing

Sizing storage for commercial applications is

more complex than residential sizing and

requires a detailed evaluation of hot water

usage patterns.

Commercial applications are too varied in

demand, peak demand, required outputtemp, etc. for set, rules to apply. Hot water

usage patterns and the total hot water

demand should both be considered. Use of

modeling software is strongly advised when

designing Commercial Systems and this is an

area where CoolSky can provide system

designs expertise to our customers.

Pipe Type and Size

Pipe Material

The solar collector loop can get very hot (i.e.

200C under stagnation conditions) and

therefore the only recommended material

choices are copper (hard or soft coiled) or

corrugated flexible stainless steel pipe.

Cool Tip

Rule of Thumb to Size the

Storage Cylinder :

10 litres per Solar Tube


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Plastic Pipe (PEX) or Galvanised Pipe should

NEVER be used in any part of the Solar

Loop within a Solar Thermal Collector

System.

Pipe Size

When selecting the size of the pipe for the

solar loop there are two main issues to be

taken into account: flow rate and pressure

drop

These two factors are closely related; a

higher pressure drop will reduce the flow

rate.

Pressure drop is increased with a smaller

diameter pipe, as well as the presence of

bends, elbows and other components that

will restrict the flow of the water such as

corrugated stainless steel piping.

A relatively direct, unobstructed flow path is

highly desirable.

If there is the possibility that additional

collectors will be added to the system in the

future then it is recommended that a lager

pipe diameter is used to accommodate the

future system expansion / upgrade.

Number of

Tubes

Pipe Size

Cu / SS

10-40 15mm / DN16

50-90 22mm / DN20

90-240 25mm / DN25

Guidelines showing pipe sizing for typical domestic

installations

Securing Pipes

Pipes must be secured in place with suitable

brackets, straps, etc. according to plumbing

code requirements for material and pipe

diameter and to prevent vibration and

placing stress on system components.

Internal Piping

Extra care must be taken to avoid any piping

leaks inside the building. Avoid joints in

attic or overhead spaces that could cause

significant property damage if they were to

leak. The CoolSky Standard Systems have

been designed to minimize the number of

hydraulic connections and we recommend

the use of Flat Face gasket seals for the

hydraulic connections where possible.

External Piping

Long external pipe runs should be avoided

where possible. Pre-insulated pipes should

have a sheath to protect the insulation from

UV degradation.

Stagnation & Overheating

What is Stagnation?

Stagnation refers to the condition that

occurs whenever the pump stops running.

This could be due to pump failure, power

outage or most commonly, as the result of a

max tank temperature protection feature

setting on the controller.


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During stagnation, the collector, unable to

actively dump heat, will continue to rise in

temperature until the heat loss from the

collector and piping equals the heat being

absorbed. In strong sunlight with high

ambient temperatures, the collector can

reach peak stagnation temperatures from

160-220C. Hence, components that may be

exposed to these high temperatures such as

valves, plumbing or insulation should be

suitably rated.

Pressure Loss with Height

Even though a system might be a closed

loop and pressurized, there is always some

pressure loss caused by height. This is

extremely important to understand when

deciding the system pressure. The loss of

pressure is about 0.1 bar per vertical meter.

A low system pressure at the collector can

result in bubbles (vapour) forming within the

heat transfer fluid due to a lowered fluid

boiling temperature. These bubbles can

collect in high points in the solar loop

piping, especially within the collector itself,

and cause air locks in the system that will

result in stagnation, because the pump does

not have the power to push fluid throughvapour pressure.

Size System to Avoid Overheating

The system should be sized so that

overheating of the tank is difficult to achieve

in a single day, even during hot, sunny

periods.

For properly sized open and closed loop

systems with suitable heat transfer fluid, it is

acceptable for the system design to allow

the solar collector to stagnate (i.e. stop the

pump) from time-to-time to prevent

overheating of the storage tank above the

maximum cylinder set temperature. An

expansion tank must be properly sized and

installed to accept the increase in fluid

volume due to thermal expansion and

potential steam formation, in order to

minimise or prevent release of fluid from thepressure relief valve.

If the system is over-sized, so that stagnation

occurs often during summer months, the

system must be able to stagnate repeatedly

without damage or heat transfer fluid

degradation. Using stagnation as a daily

means of dealing with an oversized system is

NOT recommended.

Gradual loss of vacuum in evacuated

tubes over time during normal use is not

eligible for warranty claims.

Heat Dissipation

For systems designed for space heating that

produce excessive summer heat output a

heat dissipation loop should be installed.

CoolSky offer an Apricus kit specially

designed for this purpose, the HD-25 Heat

Dissipater. This unit can be installed above

the pump station on the Flow Line from the


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collector.

The unit is a finned fluid to air style radiator

that can be used to dissipate heat from the

system once the tank has reached the

maximum temperature. The heat transfer

fluid circulates through the copper pipe

transferring heat to a set of large aluminum

fins, which in turn dissipate heat to the

surrounding air. Each HD-25 unit can

dissipate up to 1.5kW or greater with active

air flow and is suitable to dissipate theexcess energy from one (1) Apricus 30-Tube

Collector.

Note: The HD-25 is for external installation

only.

Alternative Thermal Dumps

During the summer, heat can also be

dumped into a hot-tub, jacuzzi, pool, towel

radiator, large storage tank or underground

thermal store.

Increased Angle Reduces Summer

Output

Apart from installing a smaller collector, a

good method of reducing summer heat

output is to angle the collector for optimal

winter absorption. This is achieved by

installing the collector at an angle 15-20

above the latitude angle (so long as the

collector remains within the recommended

angles of 20 to 80). This angle corresponds

closely to the angle of the sun in the sky

during the winter, thus maximizing winter

output. Conversely, during the summer

when the sun is high in the sky, the relative

surface area of the collector exposed to

sunlight is reduced, lowering overall heatproduction by about 20-25%. This option is

ideal for installations that use solar thermal

for space heating. However, this depends

upon the overall size of the collector array

and a heat dissipation unit (or units) may still

be required for larger arrays.


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Connection of Multiple Collectors

It is only recommended to connect up to

150 tubes in series (i.e. 5 x AP-30 Collectors

with a maximum flow rate of 15 l/min

through any Apricus Collector.

Damage to collectors due to heat

expansion and copper header distortion is

not eligible for warranty claims.

Balancing Flow through Collectors

When connecting multiple banks of

collectors (a bank being 1-5 x 30 tube

collectors in series) in parallel, the flow rate

through each bank MUST be equal.

Otherwise, some collectors will run cold, due

to higher flow rate while others will run hot,

due to lack of flow. This is not an issue for a

single bank of up to 150 tubes connected in

series.

Reverse Return plumbing, or first in - last

out, is an effective piping configuration that

helps to ensure balanced flow. However,

there are affordable, high quality flow setters

or circuit setters available and they are often

a better choice, as they minimize pipe run

length, costs and heat loss. Below is a

diagram of reverse return piping.


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Wind & Structural Loading

Components must be able to withstand

environmental forces such as wind loading,

snow loading, rain and hail. They must also

be securely and positively fastened to the

structure.

Collector wind loading must be considered

and the resulting stress on attachment

points thoroughly examined.

The standard Apricus Frame and Frame Kits

are all designed to withstand wind speeds of

up to 130 mph (208 km/h) without damage,

which corresponds to the mid-range of

Category 2 cyclones (US Saffir-Simpson

scale).

Table A provides peak vertical pull forces and

horizontal (pushing) forces for an AP-30

collector. These values represent both rear

and frontal winds. The highest force of 180

kg on the middle, front foot at a 60

collector angle is actually from a frontal, and

not rear, wind as it is trying to tip the

collector backward.

Based on the figures provided in Table A, the

weight of individual concrete blocks or the

strength of fixation points requirements can

be determined.

NOTE :

A safety factor of at least 1.2 should be

used, or as specified by local building

regulations, whichever is higher.

30o Angle 45o Angle 60o Angle 30o Angle 45o Angle 60o Angle

Front Middle 22 8 40 59 100 180

Front Left/Right 15 13 43 32 74 100

Rear Middle 38 85 122 18 31 66

Rear Left/Right 32 78 114 17 24 58

Combined Load 156 275 488 127 327 808

Round FootPeak Vertical Pull Load [kg] Peak Forward-Backward Load [kg]

Table A Showing the Peak Loads on the Collector Feet when subjected to wind

speeds of 130 mph (208 km/h)


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If using concrete blocks under the feet,

connecting the blocks together, particularly

front and rear, is advisable as it can help

spread the load. This applies particularly to

the middle legs which are exposed to the

peak loads. Before ballasting the system with

concrete or other weights, be aware of the

total weight live and dead load capacity of

the roof structure and determine if the roof

can safely handle this attachment method.

Other mounting methods in high wind

regions may require inspection and approval

by a licensed engineer or the local building

authority.

NOTE :

It is the responsibility of the installer to

ensure that the frame mounting is of

suitable strength.

Wind related frame and collector damage

is not eligible for warranty claims.

Snow Load

The UK and Ireland as a whole are not

generally considered to be areas prone to

heavy snow falls. However, in areas prone to

heavy or regular snow falls, or where the

accumulation of snow on the collector is of

concern, the solar collectors can be installed

at an angle of 50o or greater to promote

snow sliding off the tubes. In addition, it is

advisable to raise the front of the collector

frame 15 to 20cm off the roof surface as this

allows the collector to sit above moderate

snow falls and allow snow to blow away

from under the collector. A front track

extension available from CoolSky can be

used for this purpose.

Each tube is strong enough to withstand

>50kg loading, but roof attachment points

may need to be reinforced. Please refer to

local regulations regarding snow loadingprecautions.

Snow loading damage to the collector is

not eligible for warranty claims.

Hail Resistance

The UK and Ireland are not considered to beareas subject to extreme hail conditions.

The Apricus tubes are manufactured from

robust borosilicate glass and are able to

handle significant impact stresses. Testing

and impact stress modelling shows that the

tubes are able to withstand impact from hail

up to 25 mm in diameter, and even larger

when installed at angle of 45 or greater.

In areas prone to hail over 20 mm in

diameter, or where hail impact is of concern,

it is recommended that the solar collector be

installed at an angle of 45 or greater to

provide optimum impact resistance.


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In the unlikely case that a tube breaks, it can

easily be replaced. The solar collector can

still function properly with one or more

broken tubes, however, a reduction in heat

output will result (depending upon how

many tubes are broken). A broken tube

should be replaced by authorised persons

only.

Hail related damage to the collector is not


Lightning Protection

It is advisable to earth-ground the copper

circulation loop of the collector to avoid

lightning related damage, or electrical safety

issues. It may also help to prevent galvanic

corrosion of the copper pipe which can

result in blue staining of basins/baths etc.

Ultraviolet (UV) degradation

Any components installed outside must be

able to withstand UV radiation without

significant degradation. Colour fading is

common, but cracking, peeling and other

severe degradation should not occur during

the design-life of any component in the

system.

Coastal Regions

Apricus collectors are manufactured using

439, 301 and 304 grade stainless steels for

the solar collector frames, clips and

fasteners. These grades of Stainless Steel are

corrosion resistant to salt water, and

therefore, installation of the collectors in

costal regions is not normally an issue.

In some coastal regions, the combination of

salt spray and living sea microbes can resultin rapid corrosion of the stainless steel. In

such cases please contact CoolSky for further

advice.

Corrosion related damage is not eligible

for warranty claims.


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Back-Up Heating Source

Solar Thermal Collector Systems normally

require a back-up heating system. Typically

this is the existing gas or oil boiler that is

used to boost the Domestic Hot Water

(DHW) supply on days when there is

insufficient solar radiation.

The existing boiler is used to boost the

storage cylinder either using the top coil of a

twin coil cylinder or the bottom coil of a

secondary hot water storage cylinder that isfed by the solar pre-heat cylinder.

High Temperature Limits

Any components in close proximity to the

collector can be exposed to brief periods of

up to 160C temperatures, when the pump

turns ON after stagnation. Therefore, the

high temperature limits of all components in

the system must be known and cannot be

exceeded. It is also advisable to ensure that

components (e.g. pumping station,

expansion vessel, etc) are located

hydraulically as far from the collector in the

solar loop as is possible. Typically this will be

hydraulically close to the storage cylinder.

Temperature Control

The solar controller should have a max tank

temp function to protect the tank from

being overheated. Hot water storage

cylinders should comply with the local

building regulations and be fitted with the

appropriate safety features for over-

temperature and over-pressure protection.

Anti-Scald / Tempering Valves

Anit-scald mechanisms are required in order

to comply with the MCS MIS3001 Section

4.3.3 Requirement : Incorporate a means to

limit the water at all points of use to no

more than 60C or lower depending upon

scald risk factors.

This requirement can be met by using

Thermostatic Mixing Valves (TMVs) within

2000mm of all points of use to limit the

temperature to no more than 46C (or lessdepending upon the use). Alternatively a

TMV at the outlet from the hot water

cylinder limiting the output temperatures to

55C to 60C can be used or also by

providing a thermostatic device to limit the

solar input to the hot water cylinder. A

combination of the above may also be

acceptable.

Closed Loop Max Incoming

Pressure

For closed loop systems, the solar loop must

operate at no greater than 3.5 Bar and have

an expansion tank installed to accept fluid

expansion.

If a single wall heat exchanger is used, the

solar loop operating pressure must be below

the water main pressure.

Maximum Allowable Pressure

The maximum allowable operating pressure

for the solar collector in any system


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configuration (domestic or commercial) is 8

bar with pressure relief valve discharge rating

at no more than 8.5 Bar or lower as specified

by local building regulations.

The Pumping Station supplied by CoolSky

comes with a 6 Bar Pressure Relief Valve

(PRV) therefore when using these pump

stations the maximum allowable pressure is

5.5 Bar (or lower as specified by local

building regulations).

When using other components, check the

maximum pressure ratings for all

components of the system and only use

products that can handle the operational

temperatures and pressures of the system

design.

System pressures that exceed those

requirements outlined above will void the

warranty.

Electrical Supply

Any electrical work must be completed by a

licensed electrician and/or in accordance

with relevant electrical codes and building

regulations.

Power supply to the controller must be

protected again water ingress.

Power supply to the controller must be

disconnected when the cover is removed

and/or work with the pump or other slave

devices is conducted.

Labelling

All piping and components should be

labelled with descriptive stickers/tags to

allow easy identification during future

troubleshooting, maintenance or upgrading.

Labels must be durable enough to last for

years and withstand normal handling, wetequipment rooms and high temperatures.


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Building Considerations

Penetration Through Fire-Rated

Assemblies

Any piping that needs to penetrate fire-rated

assemblies needs to be prepared/finished in

line with any relevant regulations.

Roof Penetration

Depending on the location and local codes,

there may be various acceptable means of

penetrating the roof. Flashing are often used

to ensure a neat and water-tight penetration.

Regardless of the method used, insulation of

the solar lines and water-tightness must be

ensured. Roof penetrations may not impair

the function of the enclosure. All roof

penetrations must be sealed to prevent

water, vermin or any other intrusion.

Structural Supports

Any points of attachment for the solar

collector or other system components must

be of suitable structural strength to support

the weight of the components plus any

loads that may be encountered, such as wind

or snow loading.

Any damage to structural supports caused

by screws, drilled holes or other fastening

methods must not undermine the structural

integrity. Seek professional advice as

required.

Applicable Codes

All roof penetrations must meet applicable

codes, practices and building regulations. All

members penetrated by solar system

components must meet relevant codes.

Adjacent Materials

Materials adjacent to the solar system

components should not be exposed to

elevated temperatures.


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Health & Safety Considerations

Anyone undertaking solar heating

installations should obtain an up-to-date

copy of the relevant UK HSE (Health &

Safety Executive) Regulations and / or the

Irish HSA (Health & Safety Authority)

regulations and carefully review the contents

Working at Height

A Full Risk Analysis should be undertaken

before any work is started with particular

attention to work at height, how you plan to

organize your work, accounting for the

installation site, prevailing weather conditions

and the experience and competence of

others who will also be working at height.

Reference should be made to the Full

Current Regulations and Guidelines before

any work commences which state that a Risk

Assessment must be undertaken for any

work undertaken at height and to ensure

that arrangements are in place to :

- Eliminate or minimise the risks from

working at height

- Safe systems and methods of work are

in place for the organisation andperformance of work at height

- Safe systems and methods are in place

for selecting equipment that is suitable

to undertake the work

- Safe systems and methods are in place

for protecting people from the

consequences of working at height

The Regulations set out a basic hierarchy for

managing and selecting equipment for work

at height, as follows :

- Avoid working at height where possible

- Use work equipment or other suitable

measures to prevent falls when work

at height cannot be avoided

- Where the risk of a fall cannot be

completely eliminated, then use

equipment of other measures to

minimise the distance and

consequences should a fall occur

Under the regulations you are required to

ensure :

- All work at height is properly planned

and organized

- All work at height takes account of

weather conditions that could endanger

health and safety

- Those involved in work at height are

trained and competent

- The place where work at height is done

is safe

- Equipment for work at height is

appropriately inspected

- The risks from fragile surfaces are

properly controlled

- The risks from falling objects are

properly controlled


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General Safety Information

This section includes general Health and

Safety Information. However, reference

should be made to the current HSE / HSA

regulations which take precedence.

Appropriate safety equipment must be used

when installing the solar collector. The

installer should consider the use of the

following items in order to comply with the

Health & Safety Regulations :

- Safety glasses, gloves and other required

personal protective equipment.

- Well-maintained, properly-fitted safety

harness, lanyard, rope and appropriate

anchor for working on the roof.

- A harness attachment plan that ensures

you aware of the safe working area with

your particular harness setup.

- A first aid kit and the necessary training

in First Aid.

- Consider on-site risks such as slippery

roofs, exposed nails, hot plumbing,

sunburn, high winds, etc.

- Safety on the roof is always an importantconsideration. Avoid roof work if it is

raining and ensure that the inside of the

manifold does not get wet. Do not let

rain enter the evacuated tubes.

- Keep the evacuated tubes out of the sun

until 2-3 minutes prior to installation. If

you install the solar collector in direct

sunlight, the heat pipes will become hot

very quickly. Try to install the collector

earlier or later in the day. DO NOT install

the collector at night.

A minimum of 2 people are required to

complete an installation. Do not attempt to

complete an installation without a qualified

and experienced installation team.

Roof work should not be performed without

a second installer on-site. Each person

performing work on the roof needs to have

their own harness, rope, lanyard and anchor,

in accordance with HSE (UK) or HSA (ROI)

regulations.


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Installation Guidelines

This section contains guidelines for the

unpacking, inspection, assembly and

installation of the Apricus Solar Collectors.Several of the more common types of

Installation are covered in detail. For other

installations or where further clarification is

required please contact CoolSky.

Tube Unpack & Inspect

Check to make sure the evacuated tubes are

all intact and the getter at the bottom ofeach tube is still silver coloured by removing

the rubber caps. The rubber cap should be

immediately replaced after inspection to

protect the bottom tip of the glass tube.

If a tube has a white or clear bottom, it is

damaged and should be replaced. Any

damage or breakages should be reported

immediately upon delivery to CoolSky.

Damage to collectors and other

components incurred during transport is not


Shield Tubes from Sunlight

Do not expose the tubes to sunlight until

ready to install, otherwise the heat pipe tip

will become very hot and can cause serious

skin burns. The outer glass surface should

not become hot.

Frame/Manifold Unpack & Inspect

Unpack the standard frame that is provided

together with the manifold. Apricus solar

collectors are come with a standard frame,

which is suitable for flush mounting on roofs

that have a suitable pitch.

For installation on low-pitched roofs, flat

roofs or for wall mounts, an additional,

adjustable frame kit is available. This

additional adjustable frame will be packed

separately from the manifold and standard

frame kit.

Depending on the roofing material, the

standard frame may be attached to the roof

with flashed bracketing solutions (corrugated

steel, asphalt), roof attachment straps (tiled,

slated), stand-off bracket (tiled, slated) or

round feet (asphalt, concrete).

WARNING:

Wear safety glasses and leather

gloves at all times when handling

evacuated tubes and heat pipes.

Never touch the inside of evacuated

tubes or the heat pipe tip after

exposure to sunlight.


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An adjustable frame kit designed and

provided by Apricus is capable of turning the

standard frame into a rack, in order to

position the manifold and tubes at the ideal

azimuth and tilt for almost any location.

Frame Material

All frame components are made of 439

grade stainless steel making the frame both

strong and corrosion resistant. It is

important that frame attachment points and

externally supplied fasteners are also of

suitable structural strength and corrosion

resistance.

Galvanic Reactions

Zinc galvanized steel roofing or Uni-strut

must NOT directly contact stainless steel as

galvanic reaction between the two metals

can cause premature oxidation of the zinc

coating and the metal underneath. Apricus

offers rubber pads which are perfect for

separating the metals (see image below).

Fasteners

It is recommended that stainless steel

fasteners are used. If using galvanized steel

bolts, separate dissimilar metals using a

nylon or high density EPDM/Silicone rubber

washer.

Manifold and Bottom Support TrackAssembly

The Manifold and Bottom Track are secured

to the standard frame channels using special

securing plates. These plates are attached to

the frame channels before they leave the

factory.

They only need to be LOOSENED in order to

allow enough movement to fit the Manifold

and Bottom Support Track in place. The

plates are designed so that while somewhat

loose, they enable the Manifold and Bottom

Support Track to slide left and right for

positioning and allow the standard frame

channels to be easily adjusted side to side to

suit the roof framing layout.

Manifold Attachment

Bottom Support Rail


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Tightening Nuts

Once correctly located, the nuts should be

hand tightened ONLY using the supplied

wrench, locking the Manifold and Bottom

Support Track in place. DO NOT use a

power tool or longer hand tool to tighten

the nuts as stainless steel is prone to galling

(cold welding, i.e.), if excessive friction or

over-torqueing occurs (i.e. the nuts can lock

to the shaft before they are completely

seated, if they are over-tightened). The use

of a lubricant on the threads, such as WD-

40, will also help to prevent issues.

Split washers are supplied to ensure the

stainless steel bolts do not loosen over time.

Inverted Bolts

NOTE: Some bolts are inverted with the nut

on top. This so you can see the threads and

helps prevent you from loosening the boltso much that the nut drops off. The bolt

head is prevented from rotating by use of

nut locks (i.e. rectangular washers), removing

the need to use a second wrench

underneath the frame and aiding a quick

and easy assembly process.

Customizing the Frame

The standard frame, together with the

adjustable angle frame kit components can

be adapted to a wide range of different

installation surfaces and situations. Any

modifications to the frame design must be

approved by a licensed engineer and done

with structural integrity in mind, particularly

in high wind areas.

Cool Tip

When drilling the Stainless Steel

always use a good quality drill bit.

Take caution when using power

tools and never do any drilling of

the frame whilst on the roof.

Cool Tip

Any modifications to the mounting

frame must be approved for

strength and safety by a licensed

engineer before installation.


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Other System Components

For a typical domestic installation, in

addition to the solar collector, storage tank,

and pump station, some or all of the

following components are also required :

Solar Expansion Tank

Copper pipe (straight and/or soft rolled)

with additional insulation or Flexible Pre-

Insulated Stainless Steel Pipe.

An automatic or manual air vent

Anti-Freeze based Heat transfer fluid

Flush & Fill Pumping Cart

Anti-scald valve

Various plumbing fittings, valves, drainvalves, etc.

Scissor lift, cherry picker and/or ladders

and harness equipment for roof work

Labels and permanent marker to label

system components and flow paths.

Cool Tip

All system components should

be installed in a manner that

allows access for maintenance

and repairs.

Su ort Rail

Side Rails

Tube Cli s

Attachment Plates

Roof Attachment

Strap

Schematic showing the Apricus Standard Roof Frame (this is supplied with the Apricus

Manifold in the same box)


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Collector Installation

Flush Mounting on

Pitched Roof

Installation Planning

Carefully plan the location of the collector

frame and plumbing pipes in order to align

with the roof framing members and develop

the shortest pipe run possible to the storage

tank. Any penetrations in the roof or

building shell must be water-tight and sealed

with standard roofing materials and/or

appropriate sealants to avoid leaks and

comply with local building regulations or

requirements.

Securing to Roof

The manifold and bottom support rail can

slide left and right in relation to the frame

side rails, so there is some flexibility when

selecting the location. The frame side rails

should be located so that they lay flat, are

parallel with one another and, if possible,

aligned with the roof rafters. If the frame

side rails cannot be aligned with the roof

rafters, a noggin may need to be attached

between 2 rafters to provide an attachmentpoint. Ensure that any additions or

modifications to the roof structure meet

structural requirement and local building

regulations.

A Horizontal Brace is provided with the

standard frame kit. This gives a useful

indication of the typical spacing between

frame side rails. Additional holes may be

drilled in the horizontal brace to meet

different roofing rafter locations.

The Horizontal Brace component is NOT

structural and is simply to help with

alignment, so it can be removed if it is

incorrectly sized for the roof rafters or it is

not convenient.

Drain-Back System

If installing a drain-back system, the frame

must be rotated slightly to achieve a 2cm

drop per meter to ensure that the manifold

is sloped towards whichever header port will

be the collector outlet (hot), to promote

complete drainage.

Tiled and Slate Roof Installations

Roof Attachment Straps

Roof attachment straps are used for flush

mounting on tiled/slated roofs 2 per

standard side rail. One end of each strap

should be secured to the underside of the

Cool Tip

Ensure that the Assembled Frame is

square so that the tubes align with

the manifold header and the

bottom support track.
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standard frame side rails using the supplied

M8x20 bolts and nut lock assemblies, the

other end to the roof rafter using two

stainless steel coach screws. Once the upper

straps are attached and tightened, adjust the

bottom straps to ensure that they too are

providing support to the frame.

Fragile Slates / High Wind Area

In areas of high wind or where the roof

slates are fragile then the roof attachment

straps should NOT be used.

A rigid solar stand-off bracket (similar to

those shown below) and flashing is

recommended. Care should be taken when

cutting tiles/slates to avoid breakage, as new

tiles/slates may not be readily available. It is

recommended that in such cases a

professional roofer is used.

Manifold and Bottom Track

Attachment

Once the standard frame channels are

secured in place on the roof, the manifold

and bottom track may be attached, taking

care to ensure they are correctly aligned. The

manifold and bottom track will lock into the

frame, secured from above and below with

the attachment plates that are already in

place. Make sure that the Manifold andBottom Support Rail are square with the

frame side rails.

To ensure proper tube engagement, each

tube in the Manifold should line up with the

corresponding cradle on the Bottom

Support Rail. Each Tube is installed with the

Heat Pipe snugly engaged within the Header

with the opening of the glass tube inside the

Manifold header. The bottom of the tube,

protected by the Rubber Cap, locates in the

cradle between each set of prongs on theBottom Support Rail, where it is held in

place by the Bottom Support Rail Clip.

Mounting on Low

Pitched Roof

If the roof pitch is insufficient, an adjustableangle roof frame kit (as shown below) can

be used to increase the angle by 27to 57.

Adjustable frame kits combine with the

standard frame components to form a

complete frame assembly.

It is recommended that the adjustable frame

kits are completely assembled on the ground

before taking onto the roof see next

section.


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Metal Roof

Installations

For installation on a corrugated or ridged

steel roof, either a Basic Metal Roof Kit or a

Stand-Off Metal Roof Kit can be used to

secure the collector to the roof.

The Basic Metal Roof Kit

This kit consists of Rubber Sealing Pads that

are used to separate the frame from the roof

and also to seal the hole. Addition of some

silicone sealant or similar roof sealant

beneath the pad and inside the hole is

required thereby allowing the rubber pad to

form a tight seal against the roof, preventing

any water ingress. Three (3) attachments per

track are required.

The Stand-Off Metal Roof Kit

For installations where longer bolts may be

required to account for the height of the

ridges such that the required depth of

penetration into the rafter is achieved, or

there is a desire to hold the collector frame

away from the roof structure, the Stand-Off

Metal Roof Kit is suitable.

Each kit consists of 4 or 6 large hanger bolts

M10 x 250mm with integral rubber seals,

attachment plates, rubber pads and the

required nuts, bolts and washers for

attaching to the collector frame side rails.

Addition of some silicone sealant or similar

roof sealant beneath the pad and inside the

hole is required thereby allowing the rubber

pad to form a tight seal against the roof,

preventing any water ingress. Two (2)

attachments per track are required, thereby

needing 4 for a 20-tube collector or 6 for a30-tube collector.


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Flat Roof

Installation

The high angle frame is adjustable and

appropriate for installations on flat surfaces

and provides adjustment from 27-57. The

high angle frame kit combines with the

standard frame components to form the

complete frame assembly.

The high angle frame is supplied with Round

Feet thatare also suitable for attachment toconcrete ballast on a flat roof.

For additional strength and support a rear X-

Brace is supplied. The X-Brace has a series of

elongated holes to allow adjustment of the

location of the legs. If further adjustment is

needed, additional 9 mm holes may be

drilled using a good quality drill bit.

Assembly of the Support Frame

When undertaking an installation that

requires an adjustable angle roof frame kit

(such as on a flat roof or a low pitched roof)

it is recommended that the frame is

completely assembled on the ground on a

clear flat area. The collector frames are

relatively light and can easily be carried onto

the roof once assembled. Assembling on the

roof is both dangerous and makes it easy to

lose bolts and nuts that may roll away.

Frame Feet Anchoring

Frame feet should be bolted to the

installation surface using 8 mm diameter

stainless steel bolts or a similarly sturdy

fastening method. (Galvanized bolts should

be NOT be used as these can result galvanic

corrosion).

The surface or concrete block must be

strong/heavy enough to withstand load

during high winds. Consult a professional

structural engineer for design requirements.

Adjusting Frame Angle

The rear legs of the high angle frame

comprise two interlocking pieces (top and

bottom leg), which allow the length of the

rear leg to be adjusted, thus changing the

collector angle from between 27o and 57o.

The rear legs must never be positioned

greater than a 90o angle (perpendicular) with

the roof surface, meaning the legs must be

behind the position of the manifold, not in

front. See diagram to below.


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Rear Legs

Each rear leg has two pieces, a top and a

bottom, which allows them to be adjusted.

The two pieces must always be joined

together by 2 bolts through two sets ofholes each in each leg for structural support.

Lower Angles

If an angle less than 27o is required the low

angle frame kit should be used which

provides an installation angle of 12o.

Higher Angles

If an angle greater than 57o is required, the

mounting points of the rear feet may be

raised. Raising the angle greatly increases

the horizontal force during high winds andmay require additional structural and/or

hardware upgrades. Consult a building

engineer for design requirements.

Standard Frame

Support Rail

Standard Frame

Side Rail

Dia onal Brace

Top Rear

Leg

Bottom Rear Leg

When fitting place the large metal washers

between the inner wall of the side rail and

the outer face of the diagonal brace to

ensure a tight fit

Adjust location of diagonal

brace to chosen angle

(from 27 to 52 )

Apricus A-Frame

Supplied with

Round Fixing Feet

as Standard

Optional Rubber Pad for

attaching to metal roofs

to eliminate galvaniccorrosion risks


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Wall / Faade

Installations

The high angle frame kit may be used for

Wall / Faade Installations. The legs are

reversed so that they attach to the bottom

of the standard frame side rails rather than

the top. The legs should be position

perpendicular to the wall and are adjusted

and secured in the same manner as the Flat

Roof Installation detailed in the previous

section.

Surface Attachment

The method used for attachment to the wall

will depend on the wall material.

- The round feet can be secured with

stainless steel expansion bolts for

attachment to brick or concrete surfaces

- Stainless steel coach screws of at least

8mm diameter or greater with high

sheer strength that can penetrate into

the wall framework can be used with

wood or synthetic boarding surfaces.

Wall Strength

Always consider the weight of the collector

and the structural integrity of the wall. If the

wall construction is not suitable for the load,

it will be necessary to reinforce the wall

frame accordingly. Consult a building

engineer for design requirements.

Recommended Angle

Ideally, do not install the collector beyond an

angle of 80o (close to vertical) otherwise

heat pipe operation will be impaired by 10%

or greater. Installing vertically is permitted

and will not void the warranty, but

performance will be reduced.

Safety Considerations

If installing the collector on a wall above a

walkway, keep in mind the danger of broken

glass that could fall on pedestrians, if the

tubes were ever damaged. (E.g. during an

extreme storm due to flying debris or tree

branch falling on the collector). It may be

necessary for a barrier of to be installed

below the collector to catch any falling

materials, such as a clear roofing material.

WARNING:

For collectors installed above a pedestrian

area, take appropriate measures to

minimise injury risk in case a broken tube

or glass fell onto the ground or people

below.


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Connection to Plumbing

Plumbing Connection

Once the frame has been mounted and the

manifold attached, the manifold header may

be connected to the system plumbing.

Delayed Commissioning

If the collector is to be installed (including

evacuated tubes) prior to plumbing

connection (e.g. on new house), high

temperature resistant covers (aluminum foil)should be placed over the header inlet and

outlet to prevent any contaminants (bugs,

spiders, leaves, dust) entering the header.

The solar collector will not be damaged by a

period of dry stagnation that lasts less than

14 days.

If the collector is to be left for any significant

period of time before being commissioned it

is recommended that the collector is covered

with an appropriate tarpaulin. Ensure that

the tarpaulin is secured to the roof fixings

DO NOT secure any cover or tarpaulin to the

glass tubes as this can result in damage /

breakage of the glass under high wind

conditions.

Damage to collectors and other

components incurred by extended dry or

wet stagnation is not eligible for warranty

claims.

Pipework

Suitable Pipe Materials

Only the following materials are

recommended for use with HighPerformance Evacuated Tube Solar Collector

Systems, as follows :

- Flexible Stainless Steel Pipe

- Copper Tube (hard or soft coiled)

Plastic Pipes (PEX) and Galvanised Pipes

should NEVER be used in a solar thermalsystem

All pipework in the solar loop should be

suitable insulated in compliance with local

building regulations.

Insulation

Insulate Piping

Ensure all piping running to and from the

manifold is appropriately insulated with a

high quality insulation that complies with

local building regulations in terms of its

thermal conductivity and thickness required.

Heat loss from the piping can be significant

so particular attention should be taken to

insulate any possible points of heat loss,

particularly on outdoor piping.


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Seal the Insulation and Sensor

Port

Ensure the insulation is tight against the

manifold casing, preventing loss of heat from

the inlet and outlet. In order to prevent

water from entering the temperature probe

port and/or in between the piping and

insulation foam, a high quality silicone

sealant should be used to form a water-tight

seal. This is also important to avoid water

running down under the insulation along the

copper / stainless steel pipe into the roofspace.

Protect Insulation

EPDM (foam) insulation that is exposed to

direct sunlight should be protected against

UV related degradation. CoolSky supply

Stainless Steel Flexible Pipework that is pre-

insulated with high-grade EPDM Insulation

with UV Protective sheath.


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Installation of the Tubes

The Apricus solar collector is a simple plug

in system. The heat pipe and evacuated

tube assembly just needs to be inserted intothe manifold. The contact between the heat

pipe condenser/tip and heat pipe port in the

header needs to be tight in order to ensure

good heat transfer. Under normal use, once

the heat pipes are installed they should

never have to be removed.

Heat Pipe Preparation

Do not remove the tubes from the box

and/or expose the tubes to sunlight until

ready to install, otherwise the heat pipe tip

will become hot enough to cause serious

skin burns. The outer glass surface should

not become hot.

Heat Pipe Frost Protection

Apricus Heat Pipes contain a small amount

of copper powder, which aids in heat transfer

and provides freeze protection within the

heat pipe itself. To ensure that the powder

is at the bottom of the heat pipes, where is

needs to be, before installing the tube and

heat pipe, they should inverted (condenser

end down), returned upright (condenser at

top) and then shaken up and down a few

times to ensure the powder has all returned

to the bottom. This should be done at

ground level.

Damaged Tube

If an evacuated tube is damaged for any

reason (E.g. knocked heavily or dropped), it

will need to be replaced.

Never throw heat pipes away, as they arevery sturdy and will not be damaged even if

the glass tube has been broken. They can

be kept as spares, or inserted into plain

spare evacuated tubes to provide a new fully

functional tube.

WARNING:

Documents

Apricus CoolSky Installation Manual